Sand Casting

In sand casting, re-usable, permanent patterns are used to make the sand moulds. The preparation and the bonding of this sand mould are the critical step and very often are the rate-controlling step of this process. Two main routes are used for bonding the sand moulds:

·         The "green sand" consists of mixtures of sand, clay and moisture.

·         The "dry sand" consists of sand and synthetic binders cured thermally or chemically.

The sand cores used for forming the inside shape of hollow parts of the casting are made using dry sand components.

In the "low pressure" sand casting technique, the melted metal is forced to enter the mould by low pressure difference. This more complicated process allows the production of cast products with thinner wall thickness.

Die Casting

In this technique, the mould is generally not destroyed at each cast but is permanent, being made of a metal such as cast iron or steel. There are a number of die casting processes, as summarised in Figure 2. High pressure die casting is the most widely used, representing about 50% of all light alloy casting production. Low pressure die casting currently accounts for about 20% of production and its use is increasing. Gravity die casting accounts for the rest, with the exception of a small but growing contribution from the recently introduced vacuum die casting and squeeze casting process.

Conclusions

Aluminium castings are very powerful and versatile techniques for manufacturing semi- or finished products with intricate shapes. Those techniques are continuously improved and developed to satisfy the user needs and to penetrate new markets.

Innovations are mainly oriented to the automobile sector which is the most important market for castings. This continual improvement and development will ensure that Aluminium castings continue to play a vital role in this field.

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 Dongrun Sand Casting Capabilities: Sand Casting, Aluminum Sand Casting, Gravity Die Casting, Aluminum Die Casting